MODEL F3 & F5 NSTALLATON MANUAL RELLO 40 SERES RESDENTAL OL BURNERS NOTE: The settings in this manual are for retrofit applications. f this burner is being installed on a packaged unit (burner comes with the boiler or furnace), then follow the settings on the OEM page, as settings may differ. Burner is set for a single line system. C6501010 STANDARD F3-5 MANUAL Rev. 3-08/03/2005 1
TABLE OF CONTECT TECHNCAL DATA - Model F3... 3 TECHNCAL DATA - Model F5... 4 OL BURNER COMPONENT DENTFCATON... 5 Burner Components... 5 Serial Number dentification... 5 NTAL SET-UP... 5 ASSEMBLY OF AR TUBE TO BURNER CHASSS... 6 MOJNTNG BURNER TO BOLER OR FURNACE... 6-8 Method 1-Universal Mounting Flange... 7 Method 2-Semi-flange Collar... 8 Method 3-Pedestal Mount... 8 ELECTRCAL CONNECTONS... 8 APPLCATON FELD WR1NG... 9 NOZZLE PLACEMENT... 10 NSERTON / REMOVAL OF DRAWER ASSEMBLY... 10 ELECTRODE SETTNG... 11 TURBULATOR SETT1NG... 11 OL LNE CONNECTONS... 11-13 Single Line (Gravity Feed)... 12 Two Line (Lift System)... 12-13 PUMP PURGE... 13-14 Single Line (Gravity System)... 13 Two Line (Lift System)... 14 SETTNG THE AR ADJUSTMENT PLATE... 14 BURNER ADJUSTMENT TABLES... 15 AMULET NSTALLATON NSTRUCTONS... 16 NSTALLATON PRECAUTONS... 17 EXPLODED SPARE PARTS LST... 18 SPARE PARTS LST... 19 PACKAGE LST Your Riello 40 burner should include the following parts. Please check to make sure all parts are present before beginning the installation_ QTY. DESCRPTON (parts bag) QTY. DESCRPTON (carton) _ 2-4- 2- l- l- l- l- Mounting flange bolts (short) Semi-flange bolts (long) Nuts Chrome nuts Oil pump connector (supply) Oil pump connector (return) Female ¼" NPT adapter Male 3/8" NPT adapter l- 2.5 mm Allen key * OEM burners shipped with combustion head mounted _ 1-2- 1-1- 1- Burner chassis with cover Universal Mounting Semi- flanges Mounting gasket nstallation Manual By-pass plug * (Separate carton) 1 - Combustion Head Flange C6501010 STANDARD F3-5 MANUAL Rev. 3-08/03/2005 2
RELLO 40 F3 TECHNCAL DATA B, E E1 F= 0 TA 1 1111111111111 DMENSONS nches 8 15/32 9 59/64 6 15/32 1rim 215 252 164 El: 10-inch long (254iron) tubes are also available. 3 1/2 6 8 29/32 89 152 226 SPECFCATONS FUEL: FRNG EFFECTVE RATE: OUTPUT: VOLTAGE (Single Phase): ABSORBED ELECTRCAL POWER: MOTOR (rated): CAPACTOR: PUWP PRESSURE: PRMARY GNTON CONTROL: TRANSFORMER:, No. 2 Fuel Oil -! -0.50 to 0.95 US GPH ', 70,000 to 133,000 BTU/h 120V 60Hz (+ 10% - 15%) -_-564 Watts ', 3250 rpm Run Current 2.2 AMP -! _" 12.5 Microl_arads ', 130 to 200 psig RELLO 530 SE/C ' 8kV 16mA MOUNTNG FLANGE DMENSONS 60 B nch 1 1/4 1/4 7/16 2 3/16 in_n 32 6 11 56! ', E /. i _k \ DoE......... 1" " i i " co 7 _19 _ " Q_mm C6501010 STANDARD F3-5 MANUAL Rev. 3-08/03/2005 3
RELLO 40 F5 TECHNCAL DATA a. E E1 P9 F B A l C 1 DMENSONS nches 9 11/64 10 11/16 7 3/32 3 1/2 6 9 13/32 1rim 233 272 180 89 152 239 El: 10-inch long (254mm) tubes are also available. SPECFCATONS FUEL: FRNG EFFECTVE RATE: OUTPUT: VOLTAGE (Single Phase): ABSORBED ELECTRCAL POWER: MOTOR (rated): CAPACTOR: PUWfP PRESSURE: PRMARY GNTON CONTROL: TRANSFORMER: i, No. 2 Fuel Oil -i.-- ', 0.75 to 1.65 US GPH ', 105,000 to 231,000 BTU/h -1, 120V 60Hz (+ 10% - 15%) -L- ' 175 Watts, 3250 rpm - 2.2 AMP _i. 12.5 Microfiarads 130 to 200 psig - RELLO 530 SE/C ' 8kV 16mA C6501010 STANDARD F3-5 MANUAL Rev. 3-08/03/2005 4
OL BURNER COMPONENTS DENTFCATON RELLO 40 SERES Q- G- F3 & F5 BURNER COMPONENTS 1. Lockout indicator lamp and reset button 2. Primary control 3. Primary control sub-base 4. Pump pressure regulator 5. Motor 6. Air adjustment fixing screws 7. Hydraulic air shutter 8. Capacitor 9. Hydraulic Jack (optional) 10. Combustion Head 11. Semi Flange 12. Turbulator adjustment screw 13. Air tube cover 14. Coil 15. Vacuum gauge port 16. Pressure gauge and bleeder port 17. Return fuel line port 18. Supply fuel line port 19. Capillary tube 20. Mounting flange with gasket SERAL NUMBER DENTFCATON The Riello 15 character serial number, exmnple, 99 A 8511111 00025, is identified as follows: 99 = last two digits of the year of manufacture; A = B-week of manufacture; 8511111 = burner product code; 00025 = increment of 1 for each burner produced - specific to product code - reset to zero each January 1_t. (99) (A) (811111) (00025) Ye ofm uf c elbweekofm Burnerprod uf c encremen c code NTAL SET-UP A) Remove burner and air tube from cartons. Check parts list (inside cover) to ensure all parts are present. B) Remove burner cover by loosing the three screws securing it. Remove control box and air tube cover (see page 8). C) Remove drawer assembly from air tube, insert nozzle and set Turbulator adjustment for specific input required (see pages 8 & 9), then set aside. D) Mount air tube to burner chassis (see next page). C6501010 STANDARD F3-5 MANUAL Rev. 3-08/03/2005 5
ASSEMBLY OF AR TUBE TO BURNER CHASSS The air tube and drawer assembly are shipped in a carton separate from the burner chassis. Choose the proper air tube length to obtain the tube insertion for the specific installation. A) Remove the AR TU33E and BUNNER CHASSS from their respective cartons. B) Remove the DRAWER ASSEMBLY (1) from inside the MR TUBE by loosening the screw (2). Carefully pull the DRAWER ASSEMBLY out of the MR TUBE, install the required nozzle (see page 8) and set aside. C) Remove the two BOLTS (3) from FRONT PLATE (4) of the BURNER CHASSS. Align the two holes on the AR TUBE HOLD1NG PATE (5) with the two holes on the BURNER CHASSS FRONT PLATE with the BOLTS (3) removed. Replace the BOLTS and fingers tighten only. Re-install DRAWER ASSEMBLY into AR TU33E. Tighten SCREW (2) securely (see page 8). D) Tighten the two bolts (3) securely. )!Tl... MOUNTNG THE BURNER TO THE BOLER OR FURNACE There are three possible methods to mount the burner, depending on the individual application. These are: 1) Universal flange bolted to BoilerFFumace unit. 2) Semi-flange collar bolted to BoilerFFurnace unit. 3) Universal flange mounted to optional Pedestal mount, where flange mounting direct to appliance is not possible. Pedestal kit must be ordered separately. C6501010 STANDARD F3-5 MANUAL Rev. 3-08/03/2005 6
METHOD 1 - UNVERSAL MOUNTNG FLANGE A) nsert the two BOLTS (1) into the UNVERSAL MOUWHNG FLANGE (10) from the flat side, ensuring the bolt heads are flush with the flat surface. Secure in place using two special CHROME NUTS (2) provided. DRY BASE BOLER COMBUSTON CHAMBER.J ---,,b B) Position the MOU2qT1NG GASKET (3) between the flat surface of the UNVERSAL MOU2qT1NG FLANGE (10) and the appliance. Line up the holes in the UNVERSAL MOUNTNG FLANGE with the STUDS (4) on the appliance mounting plate and securely bolt the UNVERSAL MOU2qT1NG FLANGE to the plate. C) Secure the two semi-flanges of the ADJUSTABLE COLLAR (9) to the AR TU'3E using the two long BOLTS (6). Be sure that the ADJUSTABLE (Z)LLAR (9) is properly positioned so the outside edge of the END CONE will be at least */4 inch (6.51ran) back from the inside wall of the refractory of the combustion chamber (see dimension B above). The measured length (A) is to include MOU2qT1NG GASKET and FLANGE, if used. D) The burner may now be attached to the heating unit by insetting the AR TU'3E through the BUNNER ACCESS HOLE (8) and into the appliance, making sure the BOLTS (1) line up with the two HOLES (5) in the ADJUSTABLE COLLAR (9). Secure the burner in place using two NUTS (7). A visual verification of the air tube insertion into the combustion chmnber of the heating unit is suggested. Dimension B should be at least */4"(see drawing). NOTE: A suggested method for creating mounting bolt holes in the mounting gasket: Hold the gasket against the appliance mounting bolts using the mounting flange for proper positioning. Lightly tap the flange with a halraner to form the holes. C6501010 STANDARD F3-5 MANUAL Rev. 3-08/03/2005 7
METHOD 2 - SEM-FLANGE COLLAR A) Follow item C from METHOD 1. B) Align the air tube and attached adjustable collar so air tube is centered in the bumer access hole of the boiler/furnace unit. Mark the center of the two holes in the ADJUSTABLE COLLAR on to the front plate of the heating unit. Then drill */4inch (6.5ram) holes through the fror_ plate of the unit, using marks as a guide. C) nstall two short BOLTS (1) through the front plate of the heating unit from the inside, and secure on the outside using the two special CHROME NUTS (2). D) Follow item D from METHOD 1. METHOD 3 - PEDESTAL MOUNT Secure the MOU2qTNG FLANGE to MOU2qT1NG PEDESTAL using the hardware provided with the pedestal. Secure burner to MOU2qT1NG FLANGE as in METHOD 1, item A, C and D. NOTE: t is suggested that the pedestal be anchored in position on the floor by installing brackets over the )edestal tube and securing brackets to the floor. WARNNG: WHEN THE COMBUSTON CHAMBER S LNED WTH A REFRACTORY MATERAL, T S MPERATVE THAT THE END CONE NOT PROTRUDE NTO THE CHAMBER AREA, AS EXCESSVE HEAT AT BURNER SHUT DOWN WLL DAMAGE THE END CONE. ELECTRCAL CONNECTONS t is advisable to leave the control box offthe sub-base while completing the electrical connection to the burner. 1) Wire access hole (Use BX electrical connector) 2) Earth ground conductor tetlninal (Green wire) 3) Hot conductor terminal (Black wire) 4) Neutral conductor terminal (White wire) 5) Strain relief clamp WARNNG: The hot (black) wire must be connected to the L terminal and the neutral (white) wire must be connected to the N terminal or the primary safety control will be damaged. Do not connect wither wire to the terminal marked The burner may be controlled using either a DRECT L1NE VOLTAGE control circuit (120V AC 60 cycle) OR a LOW VOLTAGE control switching relay. Using the appropriate diagram below, make elecncal connections to bumer. All wiring must be done in accordance with existing electrical codes, both national and local. When all electrical connections have been made, the control box may be put back in place on the sub-base. WARNNG: DO NOT activate burner until proper oil line connections have been made, or failure of the pump shaft seal may occur. C6501010 STANDARD F3-5 MANUAL Rev. 3-08/03/2005 8
APPLCATON FELD WRNG DRECT LNE VOLTAGE LOW VOLTAGE Di; W_RED SUB CAPACTOR ( REMOTE SENS1NG OF SAFETY LOCKOUT: The SAFETY SWTCH in the 530SE CONTROL BOX is equipped with a contact allowing remote sensing of burner lockout. The electrical connection is made at terminal 4 (-) on the SU33-BASE. Should lockout occur the 530SE CONTROL BOX will supply a power source of 120Vac to the connection terminal. The maximum allowable current draw on this terminal (4) is 1 Amp. WARNNG: f a neutral or ground lead is attached to this terminal, the CONTROL BOX on the burner will be damaged shouhl lockout occur. C6501010 STANDARD F3-5 MANUAL Rev. 3-08/03/2005 9
NOZZLE PLACEMENT A) Determine the proper firing rate for the boiler or furnace units, considering the specific application, and then use the Burner Setup charts on page 15 to select the proper nozzle and pump pressure to obtain the required input from the burner. B) Remove the NOZZLE ADAPTER (2) from the DRAWER ASSEMBLY by loosening the SCREW (1). C) nsert the proper NOZZLE into the NOZZLE ADAPTER and tighten securely (Do not over tighten). D) Replace adapter, with nozzle installed, into drawer assembly and secure with screw (1). NSTALLATON/REMOVAL OF DRAWER ASSEMBLY Removal: A) Loosen off oil delivery tube nut from pump. B) Loosen SCREW (3), and then unplug CONTROL BOX (1) by carefully pulling it back and then up. C) Remove the AR TUBE COVER PLATE (5) by loosening the retaining SCREW (4) (Two SCREWS - Model F5). D) Loosen SCREW (2), and then slide the complete drawer assembly out of the combustion head as shown. E) To insert drawer assembly, reverse the procedure in items A to D above. C6501010 STANDARD F3-5 MANUAL Rev. 3-08/03/2005 10
ELECTRODE SETTNG MPORTANT: THS DMENSONS MUST BE OBSERVED AND VERFED. t._l-... ; f'i';, \ _x +1_'_' _--.,.f" -{-._ k_. / 1_--5/32" - 4mm rr,:_.,.,! 1.4,-;" :i..liz s' "tl%,q-" nj,, 4.-4. -.,L. 1-, 1 ' L...... t-.--.'-":--._., 13/64'.... '_', 5mm '% L.....-.[ 5/64'+ to 7/64" or 2 to2.5n'm_----_l 7" _--%. ['ml:-- TURBULATOR SETTNG A) Loosen NUT (1), and then turn SCREW (2) until the NDEX MARKER (3) is aligned with the correct index number as per the Burner Setup charts, or OEM specifications given with the appliance. B) Retighten the RETANNG NUT (1). NOTE: OEM specifications take priority over retrofit specifications shown in this manual. MODEL F3 NOTE: Zero and four are scale indicators only From left to right the first line is 4 and the last line 0. MODEL F5: Same as above, except, scale indicators are 0 and 3. OL LNE CONNECTONS This burner is shipped with the oil pump set to operate cn a single line system. To operate on a two-line system the bypass plug must be installed. WARNNG: Do not operate a single line system with the by-pass plug installed. Operating a single line system with the by-pass plug installed will result in damage to the pump shaft seal. NOTE: Pump pressure must be set at time of burner start-up. A pressure gauge is attached to the PRESSURE PORT (8) for pressure readings. Two PPE CONNECTORS (6) are supplied with the burner tbr connection to either a single or two-line system. Also supplied are two ADAPTORS (3), two temale 1/4" NPT, to adapt oil lines to burner pipe connectors. All pump port threads are British Parallel Thread design. Direct connection of NPT threads to the pump will damage fl_e pump body. Riello manometers and vacuum gauges do not require any adapters, and can be sately connected to the pump ports. An NPT 0netric) adapter must be used when connecting other gauge models.! -,i,.,.,_'i_)_ Es'. "-/ "'- --_ J'4 _. ',. -'-m t'--r--*, i.! C6501010 STANDARD F3-5 MANUAL Rev. 3-08/03/2005 11
SNGLE LNE (GRAVTY FEED SYSTEM) A) The burner is shipped configured for use in single line applications. No changes to the oil pump are required for use in single line applications. NOTE: f the pump cover (1) is removed for any reason, be sure the O-ring (2), is properly seated in the pump cover (1) before re-attaching the pump cover to the pump housing. SNGLE LNE SYSTEM-PPE LENGTHS H 3/8" OD 1/2" OD FT M FT M FT M 1.5 0.5 33 l0 65 20 3.0 1.0 65 20 130 40 5.0 1.5 130 40 260 80 6.5 2.0 195 60 325 100 H P o B) Connect the pipe connector to the SUPPLY PORT(5) of the pump. Attach the NPT adapter to the pipe connector. Attach the required piping to this pipe adapter. Be sure that the plug in the RETURN PORT (7) is tightened securely. NOTE: Do not exceed pipe lengths indicated in chart. TWO LNE (LFT SYSTEM) 2 LNE (LFT) SYSTEM-PPE LENGTHS H 3/8" OD 1/2" OD FT M FT M FT M 0.0 0.0 ll5 35 330 100 1.5 0.5 100 30 330 100 3.0 1.0 80 25 330 100 5.0 1.5 65 20 295 90 6.5 2.0 50 15 230 70 9.5 3.0 25 8 100 30 A) fa two-line system is required, install the By-pass plug provided. The by-pass plug is installed in the return pol_ of the pump. A 2.5-1rnn hexagonal key provided with the by-pass plug is to be used to install the plug. DO NOT use an inch size hexagonal key; damage to the bypass plug may result. When operating on a two-line system, supply and return lines should be the same diameter and both should extend to the same depth inside the fuel tank. Be sure there are no air leaks or blockages in the piping system. Any obstructions in the return line will cause failure of the pump shaft seal. Do not exceed the pipe lengths indicated in the tables on page 10. NOTE: Do not exceed pipe lengths indicated in chart. C6501010 STANDARD F3-5 MANUAL Rev. 3-08/03/2005 12
2,0. jn.s.t.a.!l..m..e..by: _.a..s.s. _J.u.g;, 1) Remove the return plug (7) 2) nstall the by-pass plug (4) using the 2.5 1ran hexagonal key B) Attach the two PPE CONNECTORS (6) to the pump SUPPLY and pump RETURN torts (5 and 7). Attach the required piping to these two pipe connectors using the NPT/ METRC ADAPTERS that are supplied with the burner. -... m i WARNNG: Pipe dope or Teflon tapes are NOT to be used on any direct oil connection to the fuel pump. i. 1 [...w.. 3..._jiE_-.>_..h. j.g..h.._.j..e;..tn..ei..p.e.. }_n.g..th...c..h._._. _o._1 not.._.x_st.,j..} 2..r._._...(.4..,.._.).:... ] r*... m L.W_...mS.1Eq'.>_.v._u.u.m... u!o.n. J._x_._.O.._.!.'_.!nc.h_.._...r..'.._S_g:... i i"i'_"i5"ii'_xsi -_ 3xi&iU_pp;gp_[_]_iy[i_{_,]i ga _3ar_3ao] i_ ii_;7gut'i, Tpia_3a]n_3_T]'i'n'e"_;3g_en'] L..th...e._!._._.k.._..'!..m._..b.u,m.._...P.u.m..P."... i i i =:=:=: =: =: =:=:=:=: =: =: =:=:=:=: =: =: =:=:=:=: =: =: =:=:=:=: =: =: =:=:=:=: =: =: =:=:=:=: =: =: =:=:=:=: =: =: =:=:=:=: =: =: =:=:=:=: =: =: =:=:=:=: =: =: =:=:=:=: =: =: =:=:=:=: =: =: =:=:=:=: =: =: =:=:=:=: =: =: =:=: PUMP PURGE NOTE: To protect the pump gears, it is advisable to lubricate the pump prior to purging a lift system. Apply oil through the VACUquWPORT (C). A) SNGLE LNE (GRAVTY FEED SYSTEM) lnllltmlm.. Loosen the bleeder valve (A) until oil flows out.tighten the bleeder valve securely and startburner. When bleeding the pump by pressure: 1) Loosen the bleeder valve (A). 2) Disconnect nozzle oil supply line at the pump nozzleport (B). 3) Attach a flexible plastic tube to the pump nozzle, polt directing the oil flow into a bucket. 4) Loosen the screw(s) securing the air tube cover, allowing it to be removed freely. 5) Holding the air tube cover in its proper location start the burner. 6) When the solenoid valve is engaged approximately 10 seconds after starting, remove the air tube cover and shine a light source on the photocell, allowing it to see Paise light. 7) Run the burner until the fuel pump has been purged of air, then tighten the bleeder valve and imlnediately shut down the burner. 8) Reinstall the air tube cover and nozzle line 9) The burner can now be started normally. r 1 i WARNNG: Omitting steps 2 and 3 will result in a collection of unburned oil in the combustion chamber i creating a hazardous situation upon burner startup. i L i l C6501010 STANDARD F3-5 MANUAL Rev. 3-08/03/2005 13
B) TWO LNE (LFT SYSTEM) Turn off the main power source to the burner and remove the air tube cover. Shines a light source on the photocell (now visible where the air tube cover was removed), return power to the burner and activate the bumer. With the light source in place, the burner will operate in prepurge only. When the pump is sufficiently purged, the hydraulic air shutter will open. Once the bumer is purged, turn off the power source and replace the air robe cover. Return power to the burner. The burner is now ready to operate. ATTENTON: t is ilnpol_ant that the fuel line be completely sealed and free from air leaks or any internal blockages. WARNNG! WHEN THE BYPASS PLUG S NSTALLED, A TWO-PPE SYSTEM MUST BE USED OR FALURE OF THE PUMP SHAFT WLL OCCUR. SETTNG THE AR ADJUSTMENT PLATE A) The hydraulic AR SHUTTER (1) is operated by the HYDRAULC JACK (6), assuring complete opening of the combustion air intake. Regulation of the combustion airflow is made by adjustment of the manual AR ADJUSTMENT PLATE (4) after loosening he FXNG SCREWS (3 & 5). The initial setting of the air adjustment plate should be made according to Column 5 in the Burner Setup Charts on page 13. B) The proper number on the manual AR ADJUSTMENT PLATE (4) should line up with the SETT1NG NDCATOR (2) on the Pan housing cover. Once set, the air adjustment plate should be secured in place by tightening SCREW 3 and 5. Manually open and release the hydraulic shutter to ensure it has free movement. C) The final position of the air adjustment plate will vary on each installation. Use instruments to establish the proper setting for maximum CO2 and a smoke reading of zero. NOTE: Variations in flue gas, smoke, CO2 and temperature readings may be experienced when burner cover is put in place. Therefore, the burner cover must be in place when making final combustion instmment readings, to ensure proper test results. C6501010 STANDARD F3-5 MANUAL Rev. 3-08/03/2005 14
BURNER ADJUSTMENT TABLES NON-RETROFT APPLCATONS f this burner is being installed in a packaged unit (i.e. Burner comes with a boiler or furnace), follow the installation and set-up instructions supplied with the heating appliance, as settings will differ from those shown in this manual. MODEL F3 BURNER SETUP CHART 1 ACTUAL FRNG RATE 5% ± US GPH 0.50 0.60 0.75 2 NOZZLE SZE GPH.40 x 60 /80.50 x 60 /80.60 x 60 /80 3 PUMP PRESSURE PS BAR 160 11.0 150 10.4 150 10.4 TURBULATOR SETTNG 0.0 0.5 1.5 AR DAMPER SETTNG 2.3 2.7 3.4 0.80 0.95.65 x 60 /80.75 x 60 /80 150 10.4 160 11.0 2.0 3.0 3.6 4.3 MODEL F5 BURNER SETUP CHART 1 ACTUAL FRNG RATE 5% ± US GPH 2 NOZZLE SZE GPH 3 PUMP PRESSURE PS BAR 4 TURBULATOR SETTNG 0.75.60 x 60/80 145 10 0.0 0.85.65 x 60/80 145 10 0.5 1.00.85 x 60/80 145 10 1.0 1.10 1.00 X 60/80 145 10 2.0 1.25 1.10 x 60/80 145 10 2.5 1.50 1.25 x 60/80 145 10 3.0 1.65 1.35 X 60/80 145 10 4.0 AR DAMPER SETTNG 2.25 2.5 2.75 3.0 3.5 4.25 6.0 NOTE: The above set up charts are a starting point only. The burner and appliance must be properly set up using proper combustion testing equipment. Note: any approved oil burner nozzle type, angle and manufacturer maybe used, as long as input is corresponding the correct BTU/hr. or US gph input rating of the appliance. COMBUSTON CHAMBER Follow the instructions furnished by the boiler/furnace manufacturer. Size retrofit application according to the appropriate installation codes (e.g. CSA B139 or NFPA #31). C6501010 STANDARD F3-5 MANUAL Rev. 3-08/03/2005 15
AMULET NSTALLATON NSTRUCTONS (Required on some models) The amulets provided have been selected by Riello to protect the combustion tube from hot exhaust gases and flame. This protection may be needed in applications where the combustion robe opening in the combustion chmnber refractory is larger than the tube outside diameter. The mnulet has been sized to fit Riello Model 40 sizes F3 and F5 plus the Riello Model R35. When installing this amulet, handle it carefully. Do not exert undue pressure when pushing the amulet over the combustion tube. Excessive force can result in a broken mnulet! f the amulet will not fit easily onto the tube, remove a small amount of the inner diameter with a sharp knife to provide the necessary clearance. The diagrmn below shows the proper position of the mnulet after installation. Amulet shown in mounted position _ "f_---t the,lush \ Head Receeded 1/4 inch max. ""_'2_#' --4-- NO AMULET AMULET flue gases gases LOW PRESSURE ] air tube increase in pressuredown air tube due to increase in combustion chamber pressure tapered combustion chamber causes increase in pressure inside increase in pressure down air tube due to increase in combustion chamber pressure LOW PRESSURE air tube AMULET HELPS PREVENT HOT GASES FROM TRAVELLNG DOWN AR TUBE l tapered combustion chamber causes increase in pressure inside heat i H'GHPRESSURE heat ncrease ill pressure do,eraair tube due to increase in combustion chamber pressure C6501010 STANDARD F3-5 MANUAL Rev. 3-08/03/2005 16
NSTALLLATON PRECAUTONS AR FOR COMBUSTON Do not install bumer in room with insufficient air for combustion. Be sure there is an adequate air supply for combustion if the boiler/furnace room is enclosed. t may be necessary to create a window to permit sufficient air to enter the boiler/furnace room. The installer must follow local ordinances in this regard. CANADA: t is suggested that the installer follow CSA standard B139. USA: t is suggested that the installer follow NFPA manual #31. CHMNEY Be sure chimney is sufficient to handle the exhaust gases. t is recowanended thatonly the burner be connected to the chimney. Be sure that it is clean and clear of obstructions. OL FLTER An external oil filter is REQURED, even though there is an internal strainer in the pump. The filter should be replaced at least once a year, and the filter container should be thoroughly cleaned prior to installing a new filter cartridge. DRAFT Follow the instructions furnished with the heating appliance. The pressure in the combustion area should be kept as close to zero as possible. The burner will operate with a slight draft or pressure in the chamber. ELECTRCAL CONNECTONS CANADA All electrical connections should be done in accordance with the C.E.C. Part 1, and all local codes. The system should be grounded. USA All electrical connections should be done in accordance with the National Electrical Code, and all local ordinances, The system should be grounded. CONTROL BURNER OPERATON Check out the burner and explain its operation to the homeowner. Be sure to leave the Owner's nstruction sheet with the homeowner. FRE EXTNGUSHER f required by local codes, install an approved fire extinguisher. ELECTRCAL CONNECTONS n most localities, a number 14 wire should be used inside a metal conduit. The system should be grounded. A service switch should be placed close to the burner on a fireproof wall in an easily accessible location. C6501010 STANDARD F3-5 MANUAL Rev. 3-08/03/2005 17
> Z > c/1 > 12 11 10 25 26 27 \ \ \ % 46 b_.20 21 23 24_ 11 5, 4, 49
!i!n_!;iiiiiiiiiiicodei'i'i'i'i'i'i'i'i'i _!i!iiii F5 RELLO SPARE PARTS LST F3 & F5 ndicates applicable model for each part. R 1 3007232 2 3007233 3 3006992 3006571 4 3006993 5 3005847 6 3007077 7 3007568 8 3007028 g 3007202 10 C7010002 11 3005719 12 3006925 13 3007203 14 3007029 15 3007156 16 3007268 17 3007087 18 3002278 19 3006553 20 3002279 21 3007802 22 3000443 23 3005843 3007315 24 3007316 25 3002280 Burner Back Cover Burner Back Cover Pipe Connector Supply 3/8" NPT/Metric Adapter- Male Pipe Connector Return %" NPT/Metric Adapter- Female Crushable Metal Washer 3/8" D Bleeder O-Ring - Pump Pressure Regulator Regulator Screw O-Ring - Pump Cover (3007162) Pump Screen Valve Stem Valve Stem Plate O-Ring - Valve Stem Upper O-Ring - Valve Stem Lower Nozzle Outlet Fitting Crushable Metal Washer 5/8" D Primary Control Sub-Base Coil U-Bracket and Knurled Nut Coil Pump Pump Drive Key Motor 120VOLT 60Hz Air Tube Cover Air Tube Cover Photocell 26 27 28 34 35 36 37 38 C7001029 3005854 3005855 29 3005856 C7001058 3O C7001059 31 32 33 3006911 3000878 3007204 3007207 3007208 3005844 3005708 C6950050 3007320 3007221 3007222 C7001033 C7001063 C5830005 C7001064 05830006 05320003 2623141 3000932 Primary Control Semi Flange (2 Required) Universal Mounting Flange Mounting Gasket Capillary Tube (if used) Capillary Tube (if used) Hydraulic Jack (if used) Hydraulic Air Shutter (if used) Manual Air Shutter Air intake Housing Air intake Housing Capacitor 12.5pF Fan Acoustic Acoustic Liner Liner Chassis Front Plate Chassis Front Plate Amulet - Cerafelt Sleeve Kit LT1 24V Switching relay kit complete LT1 24V Switching relay device only K7R BFOD device kit complete K7R BFOD device only Wire harness for K7R Capillary port plug Adjustable Steel Flange 40 41 /iv 3948876 3948976 3006968 3006977 42 3006966 43 3006965 44 45 3008627 3008629 3008633 3008634 3008630 46 3008631 47 3005869 48 40 41 3008623 3008626 8 3948877 3948975 3006968 3006977 42 3006966 43 3006965 3008790 44 3008628 45 46 3008846 3008635 3008789 3008632 47 3005869 48 3008788 3008625 BTi VSBT Combustion Head 3" VSBT Combustion Head 3" Turbulator Disc Turbulator Electrode Nozzle Nozzle Nozzle Regulator Regulator Electrode Electrode Electrode Air Tube Air Tube Disc Support Adapter Oil Tube Oil Tube As sembly Assembly Assembly Assembly Porcelain only only Combustion Head 8 7/8" Combustion Head 8 7/8" Turbulator Turbulator Electrode Nozzle Nozzle Nozzle Regulator Regulator Electrode Electrode Electrode Air Tube Air Tube Disc Disc Support Adapter Oil Tube Oil Tube Assembly Assembly Assembly Assembly Porcelain only only 40 41 3948873 RT 3948973 3006968 3006977 42 3006966 42 3006965 44 45 3006969 3006973 3006324 3006323 3006330 4E 3006329 47 3005869 4_ 4C 41 42 42 44 45 4E 47 4_ 3007592 3007594 3948874 3948974 3006968 3006977 3006966 3006965 3006970 3006974 3005867 3005878 3005870 3005880 3005869 3007593 3007595 Short Combustion Head 6" (271T1) Short Combustion Head 6" (271T1) Turbulator Disc Turbulator Electrode Disc Support Nozzle Adapter Nozzle Oil Tube- Short Nozzle Oil Tube- Short Regulator Assembly - Short Regulator Assembly - Short Electrode Assembly - Short Electrode Assembly- Short Electrode Porcelain Air Tube only Air Tube only Long Combustion Head 10" (271T2) Long Combustion Head 10" (271T2) Turbulator Disc Turbulator Electrode Disc Support Nozzle Adapter Nozzle Oil Tube- Long Nozzle Oil Tube - Long Regulator Assembly - Long Regulator Assembly - Long Electrode Assembly - Long Electrode Assembly - Long Electrode Porcelain Air Tube only Air Tube only C6501010 STANDARD F3-5 MANUAL Rev. 3-08/03/2005 19
35 Pond Park Rd. Hingham, MA 02043 Phone: 781-749-8292 Toll Free: 800-992-7637 Fax: 781-740-2069 PJElL8 BJRNE 5 2165 Meadowpine Blvd. Mississauga,On L5H 3R2 Phone: 905-542-0303 Toll Free: 800-387-3898 Fax: 905-542-1525 BURNER START- UP FORM * Burner S/N. or Model: Appliance: nstaller name: Company: nstallation date: Address: Phone: Fax: Owner Name: Address: Phone: E-mail: Burner Start-up nfo (OL) Burner Start-up nfo (GAS) Nozzle nfo: Gas Supply Pressure: Pump Pressure: Pump pressure: Turbulator Air Setting: setting: Air Setting: Head Setting: Draft Overfire: Draft breech: Draft Overfire: Draft breech: CO2: CO: 02: 002: CO: 02: Smoke density: (Bacharach) Manifold pressure: Single [_ Line: [_1 Two [_ Lines: [_1 onization Reading (pad.c.): nput BTU/Hr:... ii! This form was designed and provided in the installation manual for reference and also for providing technical information which can be faxed or mailed to our technical hot-line coordinator when technical assistance is required. Please complete this form, fax it or mail it at the address/fax above, or send an e- mail with the information listed below to: techservices@riellocanada.com C650 l0 l0 STANDARD F3-5 MANRYAL Rev. 3-08/03/2005 20
mello 35 Pond Park Road Hingham, MA 02043 Phone 781-749-8292 Toll Free 800-992-7637 Fax 781-740-2069 www.riellousa.com BURNERS 2165 Meadowpine Blvd Mississauga, ON L5N 6H6 Phone 905-542-0303 Toll Free 800-387-3898 Fax 905-542-1525 www.riellocanada.com Technical Support Hotline 1-800-4-RELLO 1-800-474-3556 C6501010 STANDARD F3-5 MANUAL Rev. 3-08/03/2005 21